COVER STORY » MATERIAL
COVER STORY » MATERIAL MANAGEMENTUnique ID for each package or reel» With its always up-to-date database,Factory Material Manager can determine the bestpossible solution for each setup, setup change,and replenishment «The registration and optimization process beginsas soon as the goods are received. The Factory MaterialManager software assigns a unique identificationnumber (UID) and prints it along with other dataon a label, which is then affixed to each package orreel. The UID is also linked to information about thematerial‘s quantity, material number, manufacturer,batch number, delivery date, and special featuressuch as its expiration date and whether it is a moisture-sensitivedevice (MSD). By simply scanning thelabel, the location of each package is automaticallyupdated every time it gets moved. The software thusgenerates a digital twin of the physical material flow,making it possible to manage it in a process-synchronous,networked and component-specificmanner. This permanent real-time inventory formsthe basis for all subsequent optimization steps.Path-optimized pick listsWith its always up-to-date database, Factory MaterialManager can determine the best possible solutionfor each setup, setup change, and replenishment.The program guarantees the availability ofpath-optimized pick lists and communicates withautomatic storage systems. Standardized interfacesmake it possible to integrate third-party systems intothe automated workflow. The program supports abroad portfolio of storage systems such as classicracks, SMD lifts, shuttles, carousels and paternostersmade by all well-known manufacturers, as well asthe Material Tower from the company.Factory Material Manager selects not only theright component in the right quantity, it also ensuresthat the material is always picked in accordance withthe first-in, first-out principle (FIFO), use-by datesare taken into consideration, and the storage and exposuretimes of moisture-sensitive devices are monitored.To carry the material to the line, it requests eitherpeople via WORKS Operations or autonomous mobilerobots (AMRs) via Factory Automation.Throughout the entire production process, data onthe actual material consumption by the placementmachines flows back via standardized interfaces andkeeps the previously mentioned digital twin synchronized.As a result, Factory Material Manager hascurrent inventory data at its disposal at all times.Source: ASMPTA strong pair: Factory Material Manager and WORKS Logistics ensure the seamlessly automated flow of materials throughout the factory16 EPP Europe » 05 | 2025
Source: ASMPTWORKS Logistics automatically calculates the material requirements and thus realizes a just-in-time supply for the production lineAccurate determination of materialrequirementsThe program initially receives information about thematerial requirements from a planning process thatis also divided into two stages. First, it imports orderdata from the ERP system before WORKS Planninguses the customer and production requirements togenerate a rough plan that makes the best use ofexisting production resources and minimizes costs.Next, WORKS Logistics takes care of the detailedplanning. The software optimizes the material flowon the line by ensuring the right balance betweenmaterial inflow and actual consumption based onthe production schedule created with WORKS Planning.For smaller orders, it is often sufficient to providethe necessary material for the initial setup and somerefills that cover the entire order. Larger orders, onthe other hand, must be able to rely on the continuoussupply of materials. This is where exact dosingmatters. If too little material is supplied, the line maystop due to material shortages. To avoid this, peopleoften play it safe and supply too much, but the resultingemergency stocks put a strain on the buffercapacities and block valuable space on the factoryfloor. Both situations should be avoided at all costs.In theory, the exact material requirements can becalculated in advance based on the productionschedule, but simply multiplying the throughput ratewith the bill of materials is not sufficient in real life.As mentioned earlier, the production process is subjectto many other factors that lead to fluctuationsin material consumption. For example, quality variationsat suppliers may lead to increased reject ratesthat are difficult or impossible to predict. Even usingthe actual reported material consumption is not sufficientfor demand-based procurement since it looksonly at the current state. Since removing items fromstorage and transporting them to the line takes acertain amount of time, a material tracking systemthat is based exclusively on current data would alwayslag behind actual developments, and they canbe quite dynamic.Demand forecasting basedon time slicesAs indicated above, estimating material requirementsis a central task of WORKS Logistics. It continuouslyanalyzes the current production progressand consumption data and uses this information togenerate time-slice-based forecasts of which materialwill be needed where, when, and in what quantity.It can also check when an MSD expires andorder replacements, if necessary.EPP Europe » 05 | 2025 17
